815 KAR 15:025. New installations, general design, construction and inspection criteria for boilers, pressure vessels and pressure piping.
RELATES TO: KRS Chapter 236
STATUTORY AUTHORITY: KRS 236.030, 236.120
NECESSITY, FUNCTION, AND CONFORMITY: KRS 236.030 and 236.120 authorizes the executive director, through the Board of Boiler Rules, to fix reasonable fees and standards for the safe construction, installation, inspection and repair of boilers, pressure vessels and associated pressure piping. This administrative regulation is necessary to establish the design, construction and inspection criteria requirements of the boiler inspection section for all boilers and pressure vessels not exempted by KRS 236.060. This administrative regulation incorporates provisions contained in other 815 KAR Chapter 15 administrative regulations which are being repealed simultaneously.
Section 1. Minimum Standards. (1) Boiler and pressure vessels. All new boilers and pressure vessels, except those approved pursuant to Section 5 of this administrative regulation as "state specials," shall comply with applicable provisions of 815 KAR Chapter 15 of the Kentucky administrative regulations and the ASME Boiler and Pressure Vessel Code/1989, which is hereby incorporated by reference.
(a) It is published by and available from the American Society of Mechanical Engineers (ASME), United Engineering Center, 345 East 47th Street, New York, New York 10017.
(b) A copy is also available to be inspected at the Office of Housing, Buildings and Construction, 101 Sea Hero Road, Suite 100, Frankfort, Kentucky 40601-5405, Monday through Friday from 8 a.m. to 4:30 p.m.
(c) Compliance with a later edition of this code shall be deemed equivalent and may be used in lieu of the edition specified.
(2) Details of vessels of special design not covered by the code or not fully complying with the ASME Code shall be submitted to the Boiler Section of the State Fire Marshal's Office and approval secured before field erection or construction shall begin.
(3) Pressure piping.
(a) All new pressure piping installations connected to the boiler or pressure vessel shall conform to the standards set forth in the ASME Code for Power Piping, B.31.1, 1989 edition, an American National Standard, which is hereby incorporated by reference. For low pressure boilers, the metallic piping material allowed by B.31.9 shall be acceptable.
1. The Power Piping Code is published by and available from the American Society of Mechanical Engineers, United Engineering Center, 345 East 47th Street, New York, New York 10017.
2. Copies are also available to be inspected at the Office of Housing, Buildings and Construction, 101 Sea Hero Road, Suite 100, Frankfort, Kentucky 40601-5405, Monday through Friday from 8 a.m. to 4:30 p.m.
3. Compliance with a later edition of this code shall be deemed equivalent and may be used in lieu of the edition specified.
(b) The maximum allowable design temperature and pressure of the piping system and all of its component parts shall meet or exceed the operating control settings of the boiler itself.
(c) If the maximum allowable design temperature or pressure of the boiler exceeds the maximum design limits of the piping system or any of its component parts, the pipe or its components shall not be used unless the temperature and pressure controls on the boiler are permanently set to prevent operation in excess of the design limits of the piping system and safety valves are added to activate at the maximum design limits of the piping system.
(4) Welded joints. Welded joints shall be installed by qualified welders in accordance with the ASME Code, Section IX. Welded joints shall be visually inspected for complete and full root penetration, soundness of the weld and freedom from undercutting, cracking and other surface imperfections in accordance with Section 3(5) of this administrative regulation.
Section 2. Manufacturer's Data Report. A manufacturer's data report on all boilers of steel construction and all pressure vessels conducted in accordance with ASME Boiler and Pressure Vessel Code shall be filed with the National Board of Boiler and Pressure Vessel Inspectors unless the boiler or pressure vessel is exempted by KRS 236.060.
Section 3. Installation Inspection or First Inspection and Stamping of New Boilers and Pressure Vessels. (1) Stamping. Upon completion of the installation or at the time of first inspection, a Commonwealth of Kentucky serial number shall be assigned to the boiler or pressure vessel and shall be applied to the boiler or pressure vessel as follows:
(a) Steel boilers shall be stamped with the letters, "KY" followed by the state serial number assigned, and pressure vessels shall be stamped with the letters "KY" followed by the numeral "K" and the remainder of the state serial number assigned. The stamping shall be accomplished as follows:
1. Stamping shall be applied in the immediate area of code stamping on the boiler or pressure vessel and shall be in letters and figures not less than five-sixteenths (5/16) inch in height.
2. A metal tag may additionally be used showing identical lettering and serial number as used in the stamping, this tag shall be securely affixed in the area of the manufacturer's name plate or data plate.
(b) Cast iron boilers shall have securely attached to the boiler (preferably adjacent to the manufacturer's data plate or in the most conspicuous area) a metal tag not less than one (1) inch in height on which the letters "KY" and the state serial number shall be stamped.
(c) Hot water supply boilers shall have securely attached to the heater (preferably adjacent to the manufacturer's data plate or in the most conspicuous area) a metal tag not less than one (1) inch in height on which the letters "KY" and the state serial number shall be stamped.
(d) A boiler or pressure vessel having the standard stamping of another state that has adopted a standard of construction equivalent to the standard of the Commonwealth of Kentucky may be accepted by the office if the person desiring to install the boiler or pressure vessel shall make application for the installation and shall file with this application the manufacturer's data report covering the construction of the boiler in question.
(2) Shop or field inspection. Any new power boiler, steel heating boiler, pressure vessel or piping being constructed for installation in the Commonwealth of Kentucky shall be shop or field inspected in accordance with the provisions of the applicable section of the ASME Boiler and Pressure Vessel Code and shall be stamped with the applicable ASME code stamp and the applicable national board registration number. Applicable copies of the data sheets shall be supplied to the Boiler Inspection Section.
(3) Installation inspection. New installations of boilers and of unfired pressure vessels and associated pressure piping shall be inspected by the office for compliance with applicable ASME Boiler and Pressure Vessel Code requirements and this administrative regulation.
(4) General welding. If welded assembly has been used, the installing contractor shall present for the inspector's review his welding procedures and proof of qualification of his welding operators. The contractor shall be responsible for the quality of the welding done by his organization.
(5) Welded joints. If applicable codes or engineering specifications require additional tests or if the visual inspection reveals a potential defect or if joints have been insulated prior to inspection, the inspector may require other nondestructive tests, such as radiography, to be performed by the contractor to verify the soundness of the weld. All tests or retests required by the inspector shall be at the owner's or contractor's expense.
(6) Hydrostatic pressure test. A hydrostatic pressure test, when applied to a boiler or unfired pressure vessel of riveted or welded construction, shall not exceed one and one-half (1 1/2) times the maximum allowable working pressure. The pressure shall be under proper control so that in no case shall the required test pressure be exceeded by more than two (2) percent. During the hydrostatic pressure test, the safety valve or valves shall be removed or each valve disc shall be held down by means of a testing clamp (hand tight) and not by screwing down the compression screw upon the spring. The minimum temperature of the water used to apply a hydrostatic test shall not be less than ambient temperature, but in no case less than seventy (70) degrees Fahrenheit and the maximum temperature shall not exceed 120 degrees Fahrenheit. If the only purpose of the test is to determine tightness, the test pressure shall be equal to the relieving pressure of the safety valve having the lowest relief setting.
(7) Pressure piping systems installed in association with the boiler or pressure vessel shall be inspected for proper materials, adequate pressure and temperature ranges for the boiler operation and for adequate support and tightness as follows:
(a) Hydrostatic tests. Hydrostatic tests shall be performed on the pressure piping system connected to the boiler at one and one-half (1 1/2) times the maximum allowable pressure of the boiler when the installation is complete.
(b) Code compliance. Pressure piping inspection shall include determining compliance with design plans, material specifications and ASME Code for the piping and component parts. The contractor shall document to the inspector that:
1. That the piping installation and each of its component parts conforms to the design;
2. That the materials used and method of construction meets the manufacturer's procedures and specifications; and
3. That the system is utilizing the materials and equipment specified within the temperature and pressure ranges set forth in the design and as required by Section 1(3)(c) of this administrative regulation.
Section 4. Notification of Inspection. The owner or user shall prepare each boiler for internal inspection and shall prepare for and apply a hydrostatic pressure test on the date specified by the inspector. The inspection shall not be less than seven (7) days after the date of notification.
Section 5. State Special. (1) Boilers and pressure vessels of special design equivalent to the ASME Code and vessels designed and fabricated according to the standards of the applicable sections of the ASME Boiler and Pressure Vessel Code, but not stamped with the ASME symbol stamp, shall meet the requirements of this section. The prospective owner or user who desires approval of the boiler installation as a state special shall pursue the following procedure in each individual case.
(a) Prior to installation and operation of the boiler or pressure vessel, the proposed owner, user, or his authorized agent shall make written application for permission to install the boiler or pressure vessel in the state of Kentucky. The application shall be directed to the Chief Boiler Inspector, Office of the State Fire Marshal, office of Housing, Buildings and Construction, 101 Sea Hero Road, Suite 100, Frankfort, Kentucky 40601-5405.
(b) To establish ASME Boiler and Pressure Vessel Code equivalency, the following data, material and information shall be submitted with the application for permit and approved by the Boiler Inspection Section, office of Housing, Buildings and Construction:
1. Detailed shop drawings and welding details of the proposed construction. All materials shall be in the English language and United States units of measurements listed in the ASME Code.
2. Design calculations and supporting data which shall include pressure (psi), temperature (deg. F.), use and other service conditions.
3. Specifications for all construction materials. The specifications shall conform to the applicable ASME Code standards or their suitable equivalent. If reference is made to a standard or specification of a country other than the United States, a copy shall be attached to indicate how the material is considered equivalent.
4. Copies of the welding procedures to be used and welding qualification test reports for each welding operator or welder to be used. The procedures and tests required in this paragraph shall be made in accordance with the ASME Boiler and Pressure Vessel Code, Section IX, "Welding Qualifications."
5. If the design exceeds ASME Boiler and Pressure Vessel Code limitation, recognized engineering practices shall be used and identified in the submittal.
6. Design drawings and calculations shall be certified by a professional engineer holding a license acceptable to the boiler inspection section.
7. The manufacturer of the vessel shall identify the inspection agency responsible for the shop inspections and manufacturer's data reports for the proposed vessel.
8. The shop inspection agency shall furnish the qualifications and experience of the individual inspector or inspectors assigned to make the shop inspections and shall give his jurisdiction commission number.
(2) When the boiler or pressure vessel is completed, a manufacturer's data report, signed by the manufacturer and shop inspector, shall be submitted to the jurisdictional authorities containing the equivalent type data required by the ASME Boiler and Pressure Vessel Code. ASME Boiler and Pressure Vessel Code data report forms shall not be used.
(3) Upon arrival in the state of Kentucky, the boiler or pressure vessel shall be inspected before installation by a qualified boiler and pressure vessel inspector in the employ of the office to verify that the above provisions have been complied with and that the vessel is properly marked and stamped for identification.
Section 6. General Requirements. (1) Low water fuel cutoff or water-feeding device (low pressure boilers).
(a) Automatically fired steam or vapor-system boilers shall have an automatic low-water fuel cutoff located to automatically cut off the fuel supply when the water falls to the lowest part of the water gauge glass. If a water-feeding device is installed, it shall be constructed so that the water inlet valve cannot feed water into the boiler through the float chamber and located to supply requisite feed water.
(b) A fuel cutoff or water-feeding device may be attached directly to a boiler.
(c) A fuel cutoff or water-feeding device may also be installed in the tapped openings available for attaching a water glass directly to a boiler under the following conditions:
1. The connections shall be made to the boiler with nonferrous tees or Y's not less than one-half (1/2) inch pipe size between the boiler and the water glass so that the water glass is attached directly and as close as possible to the boiler;
2. The run of the tee and Y shall take the water glass fittings and the side outlet or branch of the tee or Y shall take the fuel cutoff or water-feeding device.
(d) The ends of all nipples shall be reamed to full-size diameter.
(e) Fuel cutoffs and water-feeding devices embodying a separate chamber shall have a vertical drain pipe and a blowoff valve not less than three-fourths (3/4) inch pipe size and located at the lowest point in the water equalizing pipe connections so that the chamber and the equalizing pipe can be flushed and the device tested.
(2) Safety appliances. The safety appliances prescribed by these administrative regulations shall not be removed or tampered with except for the purpose of making repairs. The resetting of safety valves shall be done by a V-R stamp holder.
(3) Location of discharges to atmosphere. The discharge of safety valves, blowoff pipes, and other outlets shall be located so as to prevent injury to personnel.
(4) Pressure reducing valves (high pressure boilers).
(a) If pressure reducing valves are used, one (1) or more relief or safety valves shall be provided on the low pressure side of the reducing valve in case the piping or equipment on the low pressure side does not meet the requirements for the full initial pressure. The relief or safety valves shall be located either adjoining or as close as possible to the reducing valve. Proper protection shall be provided to prevent injury or damage caused by the escaping steam from the discharge or safety valves if vented to the atmosphere. The combined discharge capacity of the relief valve shall be such that the pressure rating of the lower pressure piping or equipment shall not be exceeded in case the reducing valve sticks open.
(b) The use of hand-controlled bypasses around reducing valves shall be permissible. The bypass, if used around a reducing valve, shall not be greater in capacity than the reducing valve unless the piping or equipment is adequately protected by relief valves or meets the requirements of the high pressure system.
(c) A pressure gauge shall be installed on the low pressure side of a reducing valve.
(5) Electric boilers. All appliances required for electric boilers shall be attached in accordance with the National Electrical Code and the following requirements:
(a) The grounding of the shell shall be permanently fastened on some part of the boiler and shall be grounded in accordance with the edition of the National Electrical Code in effect at the time the permit for the installation was made.
(b) A suitable screen or guard shall be provided around high tension bushings and a high voltage warning sign shall be posted. This screen or guard shall be located to prohibit anyone working around the boiler to accidentally come in contact with the high tension circuits. When adjusting safety valves, the power circuit to the boiler shall be open.
(c) The boiler may be under pressure, but the power line shall be open while the operator is making the necessary adjustments.
(d) Each KW of electrical energy consumed by an electric boiler operating at maximum rating shall be considered the equivalent of one (1) square foot of heating surface.
(a) If boilers are replaced or new boilers installed in either existing or new buildings, a minimum of two (2) feet shall be provided on all service sides, unless the installation allows for proper maintenance without the separation. Vessels having manholes shall have five (5) feet clearance from the manhole opening and any wall, ceiling or piping that will prevent a person from entering the boiler or vessel.
(b) Boilers shall be installed to:
1. Allow adequate space for their proper operation and their appurtenances;
2. Allow inspection of all surfaces, tubes, water walls, economizer, piping, valves, and other equipment; and
3. Allow for necessary maintenance and repair.
(7) Emergency devices for certain installations. Installations of power boilers or heating boilers in hospitals, rest homes, schools, mental institutions or similar institutional facilities shall comply with provisions of ASME Boiler and Pressure Vessel Code, Section IV, Article HG-634, regarding remote emergency cutoff switches. These installations shall be judged on their own merits from a standpoint of accessibility of electrical power cutoffs to the boiler or boilers in case of fire or heavy smoke emission. If installed cutoff switches are not adjacent to boiler room entryways, emergency cutoff switches shall be provided as outlined in Article HG-634, of Section IV, ASME Boiler and Pressure Vessel Code. (20 Ky.R. 2753; Am. 2975; eff. 5-18-94; TAm eff. 8-9-2007.)